3/16/2020 GENERIC PROBLEMS OF KWU SETS
GENERIC PROBLEMS OF KWU SETS
GOVERNING SYSTEMS:
Test Bed reports are generally not sent to sites. However, the same can be obtained on
demand.
At test bed, tests are conducted at higher trip oil pressure (<8bar). At site, trip oil
pressure (maximum achievable) is quite low with AOP during adjustments of stationary
characteristics. As a result, time & efforts are needed to readjust the components as per
availability of trip oil pressure. Also, matching the exact characteristics is not possible.
Characteristics (say lift Vs secondary oil pressure) of two or more same duty valves do
not match with each other. The different slopes on the curve leads to dissatisfaction of
customers.
Stop valves opening through SGC/ATRS is found to be troublesome. Most of the time
stops valves trip while resetting when starting device is operated through a program
(fast operation as compared to manual slow operation). This is due to less trip oil
pressure.
In some cases the cut-off points in case of secondary oil pressures could not be achieved
with clear distinction. The residual secondary oil pressure is found to be quite high in
such cases. (Example-cut-off point in one unit was found to be, in case of HPSOP, 2.3 bar
& residual pressure of 1.9 bar.)
Hydraulic vacuum protection malfunctions whenever oil system is started after a shut
down on this system.
In the absence of consolidation of various orifices in lines (other than those, which are
fixed at HWR,), slippage in installing the same is noticed.
Installation & orientation of test valves & solenoids need standardization based on
fulfillment of technical requirements & maintainability.
LPBP SYSTEM :
Difference in control valve lifts after certain signal oil pressure is found even after
optimizing start of openings & proportionality. This becomes a major pending point.
Stop valves are provided with drains in their respective servomotors. O&M staff never
uses these drains. Accidental opening of drains leads to wastage of oil.
Guidelines for adjusting feed back oil pressure in case of control valves is needed.
Trouble in opening of LPBP control & stop valves have been noticed during fast opening
requirements viz. whenever turbine trips on higher loads & boiler has not tripped, a delay
in opening in LPBP valves is noticed ( > 10 seconds) . This causes boiler tripping on
reheater protection. This problem could not be overcome even by resorting to the
measures suggested by HARDWAR. In fact it has become a contract closing point in case
of CHT 7.
PEDESTAL VACUUM:
As per technical requirements a vacuum of about 30-40 mm of water column is to be
maintained inside pedestals. This is to be achieved by adjustments of butterfly valves
provided in the vapour lines. These valves are found to be passing heavily in closed
position as such deeper vacuum is maintained inside pedestals. This results in moisture
ingress in oil. Valve design needs review.
DRAIN POT DRAIN VALVES:
As a part of technological improvements MSL, CRH & HRH lines are provided with drain
pot drain arrangements. Accordingly, whenever condensation of steam takes place in the
pots it is sensed & respective drain valve opens to drain the accumulated water. This
provision is given to protect the turbine against water ingress. However, this facility is
not being utilized due to failure of motors, which are not designed for frequent
starts/stops. This aspect needs review.
PROVISION OF SPECTACLE FLANGE:
Older units are equipped with a dual-purpose flange at the junction point of discharge
lines of AOP & MOP. This arrangement provided ease in operation during oil flushing.
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3/16/2020 GENERIC PROBLEMS OF KWU SETS
Newer units have economical layout wherein discharge lines do not have a junction point
so this dual-purpose flange is not provided. The absence of this flange leads to many
problems such as:
Difficulties experienced during oil flushing of MOP suction & discharge lines. Huge
fabrication work involving considerable time & efforts are needed during oil flushing.
MOT injector is not included in oil flushing.
Chances of clean oil mixing with dirty oil are fair.
This needs review of layout as well as suggested provision.
BARRING GEAR SYSTEM:
Pressure gauges installed inside pedestals on JOP lines get damaged within a short
period after commissioning.
Isolating valves in JOP lines inside pedestals are found to develop problems such as
jamming due to swollen glands, travel change, as these cannot be locked. These can be
replaced with needle valves as supplied with say TOYO turbines or JOP line valve supplied
with new type barring gear.
Frequent adjustments are needed in case of bearing 3&4 lifts whenever BG is restarted
after allowing rotor to come to standstill.
BARRING GEAR problem of CHT 7 & KKT-3.Sticking of BARRING GEAR is noticed whenever
set trips from hot condition.
This problem is suspected due to disturbance in concentricity of rotor & stator system
because of introduction of new graphite coated lubrite packers, which have failed to
perform their functions.
GLAND STEAM SYSTEM:
As per design a hot source for supplying gland steam (CRH) is envisaged. This source
should come to be in use whenever turbine trips from higher loads to minimize
distortions due to variations in GS temp which the rotor is subjected to, after a hot trip
out. But in practice CRH source is not put to use due to following reasons:
In most of the trippings boilers also trip along with turbines due to various reasons
leading to absence of CRH steam.
The fear of NONRETURN valves passing, which are provided in GS as well as CRH tapings
to GS system.
The design requirements & process limitations may be reviewed
ACCUMULATION OF DEBRIS AT GS BOXES:
Effective cleaning of GS pipelines cannot be ensured with welded type joints at seal body
ends. Steam blowing is done up to inlet to the GS CONTROL VALVE. Lines beyond GS
control station are left without blowing. This results in carryover of debris to GS boxes.
This needs review.
Pressure measurement arrangements at seal body ends are envisaged & the points are
plugged at MU. These points are to be used at site for trouble shooting purpose. In the
absence of clear-cut instructions in erection drawing & non-supply of pipes & valves
these points are not used & are covered in spray insulation.
Review is needed & standardization is done in this regard.
TEMPERATURE MONITORING
GS TEMPERATURE being of the most importance, need to find a place in one of the
recorders/ indicators. The compensograph will be the ideal one.
GS FANS:
GS Exhauster fans are not equipped with NON-RETURN VALVES. This calls for careful
operational skill during changeover operations & human errors cannot be avoided. The
need to provide NRVS in discharge lines is to be given a serious thought.
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3/16/2020 GENERIC PROBLEMS OF KWU SETS
GS DRIP LINE FILTER & TRAP:
Experience shows that the present system of a trap equipped with a strainer does not
make the operator confident of its proper functioning owing to:
Minimum dia available for drip to pass through is only 8-10 mm. in the trap.
Also float malfunctioning is observed at times
Chocking of filter goes unnoticed.
This needs review & alternate arrangements such as provision of a siphon / controller may be
thought of for GS Drip transfer.
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